WO2020115763A1

WO2020115763A1 - Aligning system in horizontal insertion packaging machine for creating pouches and method thereof

Info

Publication number: WO2020115763A1
Application number: PCT/IN2019/050879
Authority: WO
Inventors: Pranav Patel
Original assignee: Pranav Patel
Priority date: 2018-12-03
Filing date: 2019-12-03
Publication date: 2020-06-11

Abstract

The present invention discloses aligning system in horizontal insertion packaging machine, having at least one unwind web reel, for forming top and bottom web faces of pouches, formed and filled inline. Sensing means senses photo mark position, in at least one of said unwound webs, and provides feedback of said photo mark position, to its respective dancer roller or unwinder or nip roller, to align the longitudinal position of said top web face with respect to said bottom web face or said marks, or angular rotary position of sealing, locating or cutting rollers, when print matter, on either or both said webs faces, is to be registered, in longitudinal direction. The machine includes combined (i.e. transverse and longitudinal) sealer/nip/locator, product transfer conveyor, transverse sealing station, longitudinal sealing station, pouch pulling means, photo eye sensor, transverse cutter station, and dedicated servo drive integrated with said combined (i.e. transverse and longitudinal) sealer/nip/locator, said transverse sealer and a transverse cutter for changing pouch length.

Description

WO ₂₀₂₀/₁₁₅₇₆₃NING SYSTEM IN HORIZONTAL INSERTION 1_PCT/I_N2019/₀₅₀₈₇₉ MACHINE FOR CREATING POUCHES AND METHOD THEREOF

TECHNICAL FIELD OF THE INVENTION

[1] The present invention relates to packaging machines and more particularly relates to an aligning system in a packaging machine for creating pouches with products horizontally inserted therein.

BACKGROUD OF THE INVENTION

[2] Conventionally, discrete products of the pharmaceutical, personal care and food industries are packaged in center sealed pouches on flow wrappers. The product to be wrapped is placed on the conveyor which conveys the product. In this process, a web is drawn from a single reel and wrapped around the product to create a center sealed pack, enclosing the product.

[3] However, if such products are to be packaged in four sides sealed pouches, then this is, mostly, done by manual insertion in pre-made pouches. Such a process of packaging is not efficient as it requires offline manufacture of pouches into which the product is inserted, manually. This takes time and labour.

[4] Further, in a conventional horizontal insertion packaging machine, having a single web or two webs, with print matter, there are no longitudinal web alignment mechanisms and, hence, the pouch faces suffer from mismatching, in the longitudinal direction, and the pouches are wasted.

[5] Therefore, there is a need to overcome one or more abovementioned drawbacks of the conventional packaging machines. SUMMARY OF THE INVENTION

[6] Accordingly, an aspect of the present invention discloses an aligning system in a horizontal insertion packaging machine, having at least one unwind web reel, configured for forming top and bottom web faces of pouches, formed and filled inline.

[7] According to an embodiment of the present invention, a sensing means is configured for sensing a photo mark position, in at least one of said unwound webs, and providing a feedback of said photo mark position, to align the longitudinal position of said web face with respect to another web face or marks, or an angular rotary position of sealing, locating or cutting rollers, when a print matter, on either or both said webs faces, is to be registered, in a longitudinal direction.

[8] According to the embodiment, said sensing means is configured for sensing said photo mark position, in at least one of said unwound webs, and providing said feedback of said photo mark position to its respective dancer roller or unwinder or a nip roller, to align the longitudinal position of said web with respect to the other web or marks, or the angular rotary position of sealing, locating or cutting rollers, when a print matter, on either or both said webs is to be registered, in said longitudinal direction.

[9] According to another aspect, the present invention discloses a horizontal insertion packaging machine, for creating pouches from two unwound webs, from an upper web roll and a lower web roll, forming top and bottom faces of said pouch. [10] According to an embodiment of said another aspect, the present invention discloses a sensing means, configured for sensing a photo mark position, in at least one of said unwound webs, and providing a feedback of said photo mark position, to align the longitudinal position of said top web face with respect to said bottom web face or said marks, or an angular rotary position of sealing, locating or cutting rollers, when a print matter, on either or both said webs faces, is to be registered, in a longitudinal direction of the invention, before being fed to a combined (i.e. transverse and longitudinal) sealer/nip/locator.

[11] In said embodiment, said combined (i.e. transverse and longitudinal) sealer/nip seals/nips/ locates a product within said top and bottom web faces in a transverse direction and said longitudinal direction, with registered photo marks in both said directions.

[12] In said embodiment, a product transfer conveyor carries said product which then is transferred by a product pusher, over a fixed plate, to be, horizontally, inserted in between said two webs, thereby positively enclosing said product within seals/jaws of said combined (i.e. transverse and longitudinal) sealer/nip/locator.

[13] In said embodiment, a transverse sealing station followed by a longitudinal sealing station is configured for repeated sealing and for seal integrity, prior to a common film pulling nip.

[14] In said embodiment, a pouch pulling means is configured to pull said web/webs. A photo eye sensor, detects and passes a signal to a transverse cutter station, for producing a cut, in the set interval, in the transverse direction, to separate out individual pouches, along a track.

[15] In said embodiment, a dedicated servo drive is integrated with said combined (i.e. transverse and longitudinal) sealer/nip/locator, said transverse sealer and a transverse cutter for changing pouch length.

[16] In said embodiment, the longitudinal cutter station includes a provision for trimming said sealed webs on either side as well as for cutting them, longitudinally, to separate said tracks of said web.

[17] In said embodiment, a PLC signal mechanism rejects and diverts incompletely filled pouches to a rejection bin and collects completely filled pouches to another collection bin.

[18] In still another aspect, the present invention discloses a method of creating pouches on a horizontal insertion packaging machine comprising the steps of: a) Step (210): providing two unwinder stations, an upper web roll and a lower web roll for forming top and bottom web faces of said pouch;

b) Step (220): providing a sensing means configured for sensing a photo mark position, in at least one of said unwound webs, and providing a feedback of said photo mark position, to align the longitudinal position of said top web face with respect to said bottom web face or said marks, or an angular rotary position of sealing, locating or cutting rollers, when a print matter, on either or both said webs faces, is to be registered, in a longitudinal direction of the invention, before being fed to a combined (i.e. transverse and longitudinal) sealer/nip/locator; c) Step (230): providing a combined (i.e. transverse and longitudinal) sealer/nip/locator for sealing/nipping/locating product within said top and bottom web faces in a transverse direction and said longitudinal direction, with registered photo marks in both said directions; d) Step (240): providing a product transfer conveyor for carrying said product which is then transferred by a product pusher, over a fixed plate, in between said two webs, just before said combined (i.e. transverse and longitudinal) sealer/nip/locator;

e) Step (250): providing a transverse sealing station followed by a longitudinal sealing station for repeated sealing for seal integrity, prior to a common film pulling nip;

f) Step (260): trimming said sealed webs on either side as well as for cutting them, longitudinally, to separate said tracks of said web;

g) Step (270): providing a web pulling means, to pull said web, and, a photo eye sensor, to detect and pass a signal to a transverse cutter station, for producing a cut, in the set interval, in the transverse direction, to separate out individual pouches, along a track;

h) Step (280): providing a dedicated servo drive integrated with said combined (i.e. transverse and longitudinal) sealer/nip/locator, said transverse sealer and a transverse cutter for changing pouch length; and i) Step (290): providing a PLC signal mechanism to reject and divert incompletely filled pouches to a rejection bin and collects completely filled pouches to another collection bin. BRIEF DESCRIPTION OF THE DRAWINGS

[19] The above and other aspects, features, and advantages of certain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings in which:

Figure 1 shows an assembly layout of a horizontal insertion packaging machine according to an aspect of the invention.

Figure 2 shows a method of creating pouches on a horizontal insertion packaging machine according to another aspect of the invention.

[20] Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may have not been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure.

[21] Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures. DETAILED DESCRIPTION OF THE INVENTION

[22] In general, the present invention claims an aligning system in a horizontal insertion packaging machine, having at least one unwind web reel, configured for forming top and bottom web faces of pouches, formed and filled inline. A sensing means senses a photo mark position, in at least one of said unwound webs, and provides a feedback of said photo mark position, to its respective dancer roller or unwinder or a nip roller, to align the longitudinal position of said top web face with respect to said bottom web face or said marks, or an angular rotary position of sealing, locating or cutting rollers, when a print matter, on either or both said webs faces, is to be registered, in a longitudinal direction. The machine includes a combined (i.e. transverse and longitudinal) sealer/nip/locator, a product transfer conveyor, a transverse sealing station followed by a longitudinal sealing station, a pouch pulling means, a photo eye sensor, a transverse cutter station, and a dedicated servo drive integrated with said combined (i.e. transverse and longitudinal) sealer/nip/locator, said transverse sealer and a transverse cutter for changing pouch length.

[23] Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention.

[24] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the invention as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[25] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

[26] Figures discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way that would limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged environment. The terms used to describe various embodiments are exemplary. It should be understood that these are provided to merely aid the understanding of the description, and that their use and definitions in no way limit the scope of the invention. Terms first, second, and the like are used to differentiate between objects having the same terminology and are in no way intended to represent a chronological order, unless where explicitly stated otherwise.

[27] Referring Figure 1 shows an aspect of the present invention, disclosing a horizontal insertion packaging machine for creating pouches from two unwound webs; one from upper (2) and other from lower (7) web rolls. The upper and lower webs respectively form the top and bottom faces of the pouch.

[28] According to an embodiment of the present invention, each web has its respective dancer rolls (3, 8), each of the webs are pulled, respectively, by their nips (5, 9) and are fed to the combined (i.e. transverse and longitudinal) sealer/nip/locator (19) through respective dancers (6, 10) and transverse direction web aligners (14, 16).

[29] In the embodiment, both webs are sensed, by photocells (15, 17), before being fed to combined (i.e. transverse and longitudinal) sealer/nip/locator (19).

[30] In the embodiment, the provision of feedback of photo mark position ensures that precise and positive longitudinal register of both faces of the pouch/sachet is attained.

[31] In the embodiment, a sensing means is configured for sensing a photo mark position, in at least one of said unwind reels (2, 7), and providing a feedback of said photo mark position, to align the longitudinal position of top web face (2) with respect to bottom web face (7) or said marks or the angular rotary position of sealing, locating or cutting rollers, when a print matter, on either or both said webs is to be registered, in said longitudinal direction.

[32] According to the embodiment, said sensing means is configured for sensing said photo mark position, in at least one of said unwound webs, and providing said feedback of said photo mark position to its respective dancer roller (3, 6, 8, 10), or unwinder (2, 7) or nip roller (5, 9), to align the longitudinal position of said top web with respect to said bottom web or said marks, or the angular rotary position of sealing, locating or cutting rollers, when a print matter, on either or both said webs is to be registered, in said longitudinal direction.

[33] In the embodiment, said sensing means is configured for sensing said photo mark position, in either or both of two webs, arising from a common parent unwind reel which is slit to form the two webs, forming each of the two faces of the pouch and thereby said sensing means enables register of one upper web face, with respect to said bottom web face or said marks, or an angular rotary position of sealing, locating or cutting rollers, when a print matter, on either or both said webs faces, is to be registered, in a longitudinal direction of the invention.

[34] In the embodiment, the photo-marks of both webs (2, 7) are matched, prior to their entry into the combined (i.e. transverse and longitudinal) sealer/nip/locator (19). At the combined (i.e. transverse and longitudinal) sealer/nip/locator (19), both webs (2, 7) get sealed in the transverse and longitudinal directions, with register in both directions, according to their photo marks.

[35] In the embodiment, simultaneously, the webs receive the product (13) and enclose it within the seals/jaws of the combined (i.e. transverse and longitudinal) sealer/nip/locator (19). This ensures that product (13) position, between the two webs (2, 7), is positively located, according to their print matter, and remains fixed, as the webs undergo subsequent operations i.e. the product does not move relative to the webs.

[36] In the embodiment, the webs (2, 7) may be of multiple tracks, corresponding to product (13) feed. The pair of rollers with seals or jaws, seal or locate the product, within the webs, in both the longitudinal and transverse directions, to form a pocket enclosure of a track, between the upper and lower roller of the pair, as the web exits combined (i.e. transverse and longitudinal) sealer/nip/locator. The pocket is the precursor of the pouch.

[37] According to the aspect, the present invention discloses a product transfer conveyor, (1) carrying the product which is then transferred by product pusher

(11), over fixed plate (12), in between the two webs, just before the combined (i.e. transverse and longitudinal) sealer/nip/locator (19).

[38] In said embodiment, a transverse sealing station (20) is followed by a longitudinal sealing station (21) for repeated sealing for seal integrity, prior to a common film pulling nip (23).

[39] In said embodiment, a pouch pulling means, pulls said web/webs, and, a photo eye sensor (25), to detect and pass a signal to a transverse cutter station (26) for producing a cut, in the set interval, in the transverse direction, to separate out individual pouches, along a track.

[40] In said embodiment, a dedicated servo drive is integrated with each, the combined (i.e. transverse and longitudinal) sealer/nip/locator (19), the transverse sealer (20) and the transverse cutter (26) for easy change of pouch length.

[41] In said embodiment, longitudinal cutter (24) station includes a provision for trimming said sealed webs on either side as well as for cutting them, longitudinally, to separate said tracks of said web.

[42] According to the embodiment, the present invention discloses a PLC signal mechanism (27) to reject and divert incompletely filled pouches to a rejection bin (28) and collect completely filled pouches to another collection bin (30).

[43] According to the embodiment of the invention, edge trim webs are wound in rewinder (29).

[44] According to the present invention, the webs can be of two different laminates for the two web faces.

[45] According to another aspect of the present invention, a method (200) of creating pouches on a horizontal insertion packaging machine is disclosed. The method comprises the steps of:

a) Step (210): providing two unwinder stations, an upper web roll and a lower web roll for forming top and bottom web faces of said pouch;

b) Step (220): providing a sensing means configured for sensing a photo mark position, in at least one of said unwound webs, and providing a feedback of said photo mark position, to align the longitudinal position of said top web face with respect to said bottom web face or said marks, or an angular rotary position of sealing, locating or cutting rollers, when a print matter, on either or both said webs faces, is to be registered, in a longitudinal direction of the invention, before being fed to a combined (i.e. transverse and longitudinal) sealer/nip/locator;

c) Step (230): providing combined (i.e. transverse and longitudinal) sealer/nip/locator for sealing/nipping/locating product within said top and bottom web faces in a transverse direction and said longitudinal direction, with registered photo marks in both said directions; d) Step (240): providing a product transfer conveyor for carrying said product which is then transferred by a product pusher, over a fixed plate, in between said two webs, just before said combined (i.e. transverse and longitudinal) sealer/nip/locator;

h) Step (280): providing a dedicated servo drive integrated with said combined (i.e. transverse and longitudinal) sealer/nip/locator, said transverse sealer and a transverse cutter for changing pouch length; and i) Step (290): providing a PLC signal mechanism to reject and divert incompletely filled pouches to a rejection bin and collect completely filled pouches to another collection bin.

[46] The present invention is for automating packaging of said products in four sides sealed flexible pouches, formed in line, from two pre-printed heat sealable laminated webs, emanating from one or two independent parent reels and forming the top and bottom faces of the pouch/sachet. The product, comprising of one or multiple components, is horizontally inserted between the two webs. Products include pharmaceutical, personal care or food products which are discrete i.e. count able and which may be of more than one component e.g. rapid diagnostic kit (RDK), pharmaceutical tablet/capsule blister strip, vial etc.

[47] The two pre-printed heat sealable laminated webs are unwound and positively registered with each other, in the transverse and the longitudinal directions, according to their printed matter, before they are sealed together. At the point of insertion, the product position within the seals/jaws/locator of the sealer/nip/locator is positively located and fixed whereby it does not shift relative to the webs and foul with sealers and cutters, completing the pack formation, in subsequent stages. Precise and positive transverse and longitudinal register of both faces of the pouch/sachet is attained. Use of two different laminates for the two faces is rendered feasible.

[48] In the foregoing detailed description of aspects embodiments of the invention, various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the invention require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the detailed description of aspects, embodiments of the invention, with each claim standing on its own as a separate embodiment. [49] It is understood that the above description is intended to be illustrative, and not restrictive. It is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined in the appended claims. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms“including” is used as the plain-English equivalent of the respective term“comprising” respectively.

Claims

Claims :

1. An aligning system in a horizontal insertion packaging machine, the aligning system comprising:

at least one unwind web reel, configured for forming top and bottom web faces of pouches, formed and filled inline; and

a sensing means configured for sensing a photo mark position, in at least one of said unwound webs, and providing a feedback of said photo mark position, to align the longitudinal position of said web face with respect to another web face or marks, or an angular rotary position of sealing, locating or cutting rollers, when a print matter, on either or both said webs faces, is to be registered, in a longitudinal direction.

2. The aligning system as claimed in claim 1, wherein sensing means is configured for sensing said photo mark position, in at least one of said unwound webs, and providing said feedback of said photo mark position to its respective dancer roller or unwinder or a nip roller, to align the longitudinal position of said web with respect to the other web or marks, or the angular rotary position of sealing, locating or cutting rollers, when a print matter, on either or both said webs is to be registered, in said longitudinal direction.

3. A horizontal insertion packaging machine, for creating pouches comprising: two unwound webs, an upper web roll and a lower web roll, for forming top and bottom faces of pouches; a sensing means, configured for sensing a photo mark position, in at least one of said unwound webs, and providing a feedback of said photo mark position, to align the longitudinal position of said top web face with respect to said bottom web face or said marks, or an angular rotary position of sealing, locating or cutting rollers, when a print matter, on either or both said webs faces, is to be registered, in a longitudinal direction, before being fed to a combined (i.e. transverse and longitudinal) sealer/nip/locator, said combined (i.e. transverse and longitudinal) sealer/nip seals/nips/ locates a product within said top and bottom web faces in a transverse direction and said longitudinal direction, with registered photo marks in both said directions;

a product transfer conveyor for carrying said product which then is transferred by a product pusher, over a fixed plate, to be, horizontally, inserted in between said two webs, thereby positively enclosing said product within seals/jaws of said combined (i.e. transverse and longitudinal) sealer/nip/locator;

a transverse sealing station followed by a longitudinal sealing station for repeated sealing and for seal integrity, prior to a common film pulling nip; a pouch pulling means, to pull said web/webs, and a photo eye sensor, to detect and pass a signal to a transverse cutter station, for producing a cut, in the set interval, in the transverse direction, to separate out individual pouches, along a track; and a dedicated servo drive integrated with said combined (i.e. transverse and longitudinal) sealer/nip/locator, said transverse sealer and a transverse cutter for changing pouch length.

4. The packaging machine as claimed in claim 3, wherein said longitudinal cutter station includes a provision for trimming said sealed webs on either side as well

as for cutting them, longitudinally, to separate said tracks of said web.

5. The packaging machine as claimed in claim 3-4, wherein said machine includes a PLC signal mechanism to reject and divert incompletely filled pouches to a rejection bin and collect completely filled pouches to another collection bin.

6. A method (200) of creating pouches on a horizontal insertion packaging machine comprising the steps of: a) Step (210): providing two unwinder stations, an upper web roll and a lower web roll for forming top and bottom web faces of said pouch; b) Step (220): providing a sensing means configured for sensing a photo mark position, in at least one of said unwound webs, and providing a feedback of said photo mark position, to align the longitudinal position of said top web face with respect to said bottom web face or said marks, or an angular rotary position of sealing, locating or cutting rollers, when a print matter, on either or both said webs faces, is to be registered, in a longitudinal direction of the invention, before being fed to a combined (i.e. transverse and longitudinal) sealer/nip/locator; c) Step (230): providing a combined (i.e. transverse and longitudinal) sealer/nip/locator for sealing/nipping/locating product within said top and bottom web faces in a transverse direction and said longitudinal direction, with registered photo marks in both said directions; d) Step (240): providing a product transfer conveyor for carrying said product which is then transferred by a product pusher, over a fixed plate, in between said two webs, just before said combined (i.e. transverse and longitudinal) sealer/nip/locator; e) Step (250): providing a transverse sealing station followed by a longitudinal sealing station for repeated sealing for seal integrity, prior to a common film pulling nip; f) Step (260): trimming said sealed webs on either side as well as for cutting them, longitudinally, to separate said tracks of said web; g) Step (270): providing a web pulling means, to pull said web, and, a photo eye sensor, to detect and pass a signal to a transverse cutter station, for producing a cut, in the set interval, in the transverse direction, to separate out individual pouches, along a track; h) Step (280): providing a dedicated servo drive integrated with said combined (i.e. transverse and longitudinal) sealer/nip/locator, said transverse sealer and a transverse cutter for changing pouch length; and i) Step (290): providing a PLC signal mechanism to reject and divert incompletely filled pouches to a rejection bin and collect completely filled pouches to another collection bin.